Mattresses with mutilple customizable and replaceable levels and sections and methods thereof

ABSTRACT

A mattress including a customizable and replaceable mattress core, two or more customizable and replaceable foam sections, a customizable and replaceable panel and at least one connection device. The two or more customizable and replaceable foam sections are positioned on a surface of the customizable and replaceable mattress core. The customizable and replaceable panel is positioned over the two or more customizable and replaceable foam sections. The connection device has detachably mating connector portions. One of the detachably mating connector portions is secured adjacent at least a portion of an outer periphery of the customizable and replaceable panel. Another of the detachably mating connector portions is secured adjacent at least a portion of another outer periphery of the surface of the customizable and replaceable mattress core. The detachably mating connector portions of the connection device detachably secure the customizable and replaceable panel to the customizable and replaceable mattress core and retain the position of the two or more customizable and replaceable foam sections.

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 62/249,037, filed Oct. 30, 2015, and U.S.Provisional Patent Application Ser. No. 62/274,887, filed Jan. 5, 2016,which are hereby incorporated by reference in their entirety.

FIELD

This technology generally relates to mattresses and, more particularly,to mattresses with multiple customizable and replaceable levels andsections and methods thereof.

BACKGROUND

Today, most mattresses that are sold are innerspring mattresses,although there is increasing interest in and demand for other types ofmattresses, such as foam mattresses made from polyurethane foam orlatex. Customers contain to seek mattresses that will provide them witha better night's sleep.

Unfortunately, despite ongoing research and development efforts,mattresses often still fall short of customers' expectations for sleepcomfort and support as well as durability. Additionally, even thoughthere are greater numbers and types of mattresses available, they stillcan not be adjusted or customized sufficiently for the changing needs ofcustomers or for the different types and/or numbers of customers thatmight be using the mattress to sleep. Further, when at least a portionof a mattress begins to wear out, existing mattresses still requirereplacement of the entire mattress which is expensive.

SUMMARY

A mattress including a customizable and replaceable mattress core, twoor more customizable and replaceable foam sections, a customizable andreplaceable panel and at least one connection device. The two or morecustomizable and replaceable foam sections are positioned on a surfaceof the customizable and replaceable mattress core. The customizable andreplaceable panel is positioned over the two or more customizable andreplaceable foam sections. The connection device has detachably matingconnector portions. One of the detachably mating connector portions issecured adjacent at least a portion of an outer periphery of thecustomizable and replaceable panel. Another of the detachably matingconnector portions is secured adjacent at least a portion of anotherouter periphery of the surface of the customizable and replaceablemattress core. The detachably mating connector portions of theconnection device detachably secure the customizable and replaceablepanel to the customizable and replaceable mattress core and retain theposition of the two or more customizable and replaceable foam sections.

A method for making a mattress includes selecting one of a plurality ofdifferent customizable and replaceable mattress cores. Two or morecustomizable and replaceable foam sections are positioned on a surfaceof the selected one of the plurality of customizable and replaceablemattress cores. A customizable and replaceable panel is positioned overthe two or more customizable and replaceable foam sections. Detachablymating connector portions of at least one connection device aredetachably mated. One of the detachably mating connector portions issecured adjacent at least a portion of an outer periphery of thecustomizable and replaceable panel. Another of the detachably matingconnector portions is secured adjacent at least a portion of anotherouter periphery of the surface of the selected one of the plurality ofdifferent customizable and replaceable mattress cores. The detachablymating connector portions of the connection device detachably secure thecustomizable and replaceable panel to the selected one of the pluralityof different customizable and replaceable mattress cores and retain theposition of the two or more customizable and replaceable foam sections.

This technology provides a number of advantages including providing amattress with customizable and replaceable levels and sections. Withthis technology, the mattress can easily adjust comfort levels and/orstyles over different levels and sections of the mattress to provide auniquely customized mattress. Additionally, with this technologycomplete replacement of a mattress is no longer required becausecustomers can less expensively replace different levels and/or sectionsas needed or desired.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an example of a mattress with multiplecustomizable and replaceable levels and sections;

FIG. 2 is an enlarged view of an example of a zipper connector for theexample of mattresses with multiple customizable and replaceable levelsand sections shown in FIG. 1;

FIG. 3 is a partial, side cross-sectional view of examples ofcustomizable and replaceable levels of a mattress;

FIGS. 4A-4C are diagrams of examples of different types of customizableand replaceable mattress cores; and

FIGS. 5A-5C are top views of different examples of configurations ofcustomizable and replaceable foam sections.

DETAILED DESCRIPTION

An example of a mattress 10 with customizable and replaceable levels andsections is illustrated FIGS. 1-3. In this example, the mattress 10 hasthree levels including a customizable and replaceable mattress core12(1), customizable and replaceable foam sections 14(1)-14(2), and acustomizable and replaceable fabric panel 16, although the mattress canhave other types and/or numbers of levels and/or sections and mayinclude other types and/or numbers of other components and/or otherelements in other arrangements, such as the zipper connector 18. Thistechnology provides a number of advantages including providing amattress that allows mixing and matching of customizable and replaceablemattress cores, customizable and replaceable foam sections, and/orcustomizable and replaceable fabric panels to adjust comfort levelsand/or styles as well as to facilitate easy and less expensiverefurbishment rather than complete replacement.

Referring more specifically to FIGS. 1-4C, the mattress 10 includes thecustomizable and replaceable mattress core 12(1) that forms the base ofthe mattress 10, although the mattress could have other types and/ornumbers of other bases or other foundations. In this particular exampleas shown in FIG. 1, the customizable and replaceable mattress core 12(1)comprises three layers 13(1)-13(3) and each layer may comprise the sameor different types of material as selected. Additionally, thecustomizable and replaceable mattress core 12(1) could be a unitaryconstruction comprising a foam mattress core 12(1) as shown in FIG. 4A,as an open coil mattress core 12(2) shown in FIG. 4B or a pocket coilmattress core 12(3) as shown in FIG. 4C by way of example only, althoughother types of mattress cores can be used, such as a mattress core witha water filled section. Further, a customizable and replaceable mattresscore 12(4) may comprise three different sections 15(1)-15(3) where atleast two of the sections are different types of mattress cores, such asfoam, open coil, and/or pocket coil by way of example only. Thesemultiple mattress core sections which form the customizable andreplaceable mattress core may have different symmetric or asymmetricconfigurations, such as those illustrated and described later herein forthe customizable and replaceable foam sections with reference to FIGS.5A-5C by way of example. Accordingly, with this technology a particulartype of mattress core with certain layer or layers and/or section orsections of different types of materials can be selected and/or laterreplaced as needed. By way of example only, on one side of a mattress asleeper may prefer a memory foam mattress core section for a certaintype of support while on the other side of the mattress the othersleeper may prefer an open coil mattress core section which providesmore air flow.

The mattress 10 may also include two customizable and replaceable foamsections 14(1)-14(2) that are placed on and substantially covering themattress core 12, although other types and/or numbers of customizableand replaceable foam sections in other sizes and/or arrangements couldbe used, such as just one section or three or more sections. In thisexample, the two customizable and replaceable foam sections 14(1)-14(2)are placed adjacent or parallel to each other along a length of themattress core 12 as shown in FIGS. 1 and 4A, although the twocustomizable and replaceable foam sections can be placed using otherarrangements. For example, the mattress 10 may also include threecustomizable and replaceable foam sections 14(3)-14(5) arranged in aparallel zone configuration as shown in FIG. 5B to provide customizedfoam sections for each sleeper and also a transition zone comprisingcustomizable and replaceable foam section 14(4) between customizable andreplaceable foam sections 14(3) and 14(5) to smooth the transitionbetween the different customizable and replaceable foam sections 14(3)and 14(5). In another example, the mattress 10 may also include threecustomizable and replaceable foam sections 14(6)-14(8) arranged in anasymmetric zone configuration as shown in FIG. 5C to again providecustomized foam sections for each sleeper and also provide a transitionzone with customizable and replaceable foam section 14(7) to smooth thetransition between the different customizable and replaceable foamsections 14(6) and 14(8) adjacent the upper body portions of thesleepers.

Each of the customizable and replaceable foam sections 14(1)-14(8) maybe selected to have a different amount of firmness so a foam comfortlevel, such as a soft, medium, or firm comfort levels by way of exampleonly, of the mattress 10 can be adjusted to the particular sleepers,such as the his side and her side having different foam comfort levelsas illustrated in the example in FIG. 1. Each of the customizable andreplaceable foam sections 14(1)-14(8) may also have different foamdensities. Foam density is a specific measurement of how much weight inpounds foam can handle per cubic foot and may impact quality anddurability of the foam sections 14(1)-14(8) and thus how long beforereplacement. As a result, foam sections 14(1)-14(8) with a particularfoam density could be selected for example to extend the time beforereplacement might be needed or in another example to minimize cost byselecting a foam density with an acceptable anticipate life span at alower cost. Additionally, each of the customizable and replaceable foamsections 14(1)-14(8), may have one or more other features, such as aribbed or otherwise contoured surface to adjust the comfort or feel byway of example only. Further, other numbers of customizable andreplaceable foam sections in other configurations may be used and againeach of the customizable and replaceable foam sections can be easilyreplaced as desired and/or needed because of wear or other use.

In this particular example, the customizable and replaceable foamsections 14(1)-14(2) each have three different types of foam layers17(1)-17(4) as shown in FIG. 3 to insure extended support and comfort,although each could have other types and/or numbers of layers.Additionally, in this particular example, the bottom layer 17(4)comprises an extra hard 100% breathable foam layer that provides supportwith ventilation, the middle layers 17(2) and 17(3) comprises hard foamlayers that provides a touch of softness while maintaining the bodysupport, and the top layer 17(1) comprises a soft foam layer for apremium luxury welcoming feeling, although other types and/or numbers oflayers can be used for each of the customizable and replaceablesections.

While in this particular example there are no connectors to hold thedifferent combinations and configurations of the customizable andreplaceable foam sections 14(1)-14(8) together as shown in the examplesin FIGS. 5A-5C apart from the customizable and replaceable fabric panel16 with the zipper connector 18, one or more other connectors may beused. For example, the different combinations and configurations of thecustomizable and replaceable foam sections 14(1)-14(8) may be heldtogether by hook and loop fasteners, glue, elastic bands, and/or rivetbuttons by way of example only, although other types and/or numbers ofconnectors may be used.

The mattress 10 may also include the customizable and replaceable panel16 made of a fabric or other material or materials, such as cotton,synthetic fibre, cashmere coir, or polyester by way of example only,although other types and/or numbers of panels comprising other typesand/or numbers of materials may be used. In this example, thecustomizable and replaceable panel 16 comprises a sheet which is made oftwo layers of one (1) cm thick thirteen (13) density foam and iswashable, although other types and/or numbers of panels made of othertypes, layers and/or numbers of materials could be used. With thistechnology, the customizable and replaceable panel 16 can be changed asneeded or desired to adjust the comfort level and also to permit lessexpensive partial replacement of the mattress 10.

The zipper connector 18 is used to detachable secure an outer peripheryor edge of the customizable and replaceable panel 16 to an outerperiphery or edge of the customizable and replaceable mattress core12(1), although other types and/or numbers of detachable connectorswhich may be in other locations could be used, such as buttons or hookand loop fasteners by way of example only. Additionally, although azipper connector 18 is shown other manners for securing the one or morecustomizable and replaceable foam sections, such as the differentcombinations and configurations of the customizable and replaceable foamsections 14(1)-14(8), to the mattress core 12(1) may be used. Further,in this example the zipper connector 18 may comprise detachably matingzipper connector portions 19(1) and 19(2) which are each respectivelyattached to an outer edge or periphery of the customizable andreplaceable panel 16 and the customizable and replaceable mattress core12(1). The zipper connector 18 with the detachably mating zipperconnector portions 19(1) and 19(2) may be used to detachably secure thefabric panel 16 to the mattress core 12(1) to hold the one or morecustomizable and replaceable foam sections, such as the differentcombinations and configurations of the customizable and replaceable foamsections 14(1)-14(8), in place, although other types and/or numbers ofsecuring mechanisms could be used, such as hook and loop fasteners,glue, or elastic straps by way of example only.

An example of a method for using the mattress 10 will now be illustratedand described with reference to FIGS. 1-5C. In this example, one of aplurality of mattress cores 12(1)-12(3) may be selected, although othertypes and/or numbers of mattress cores could be used. Additionally, themattress core that is selected could have different numbers and/or typesof layers as shown in the example in FIG. 1 and/or may comprise two ormore different mattress core sections 15(1)-15(3) as shown in FIG. 3 toprovide numerous options for customizing the mattress core for themattress 10 for each particular sleeper.

Next, the one or more customizable and replaceable foam sections, suchas the different combinations and configurations of the customizable andreplaceable foam sections 14(1)-14(8), may be placed on a surface of theselected one of the customizable and replaceable mattress core 12(1).Again these different numbers and/or combinations of foam sections canbe selected to customize the sleeping surface for each sleeper for themattress 10. As described in greater detail earlier, each of thecustomizable and replaceable foam sections 14(1)-14(8) may havedifferent types and/or numbers of layers which provide different levelsof firmness, feel, and/or comfort and may be selected based on those orother types and/or numbers of factors. In this example, no connectorsare used to hold the selected one of the combinations and configurationsof the customizable and replaceable foam sections 14(1)-14(8) in place,although one or more connectors could be used.

Next, in this example the zipper connector 18 with the detachably matingzipper connector portions 19(1) and 19(2) can be used to secure theselected one of the combinations and configurations of the customizableand replaceable foam sections 14(1)-14(8) in place. In particular, thezipper connector portions 19(1) and 19(2) which are each respectivelyattached to an outer edge or periphery of the customizable andreplaceable panel 16 and the customizable and replaceable mattress core12(1) can be detachably mated together, although again other typesand/or numbers of connectors in other locations could be used.

Accordingly, this technology provides a number of advantages includingproviding a mattress that allows mixing and matching of customizable andreplaceable mattress cores, customizable and replaceable foam sections,and/or customizable and replaceable fabric panels to adjust comfortlevels and/or styles as well as to facilitate easy and less expensiverefurbishment rather than complete replacement. With this technology, amattress can be provided with a selected level of softness, comfort, andsupport for each sleeper. Further, each of the levels and regions of themattress are customizable and replaceable extending the overall life ofthe mattress and providing a more economical mattress solution forcustomers.

Having thus described the basic concept of the technology, it will berather apparent to those skilled in the art that the foregoing detaileddisclosure is intended to be presented by way of example only, and isnot limiting. Various alterations, improvements, and modifications willoccur and are intended to those skilled in the art, though not expresslystated herein. These alterations, improvements, and modifications areintended to be suggested hereby, and are within the spirit and scope ofthe technology. Additionally, the recited order of processing elementsor sequences, or the use of numbers, letters, or other designationstherefore, is not intended to limit the claimed processes to any orderexcept as may be specified in the claims. Accordingly, the technology islimited only by the following claims and equivalents thereto.

What is claimed is:
 1. A mattress comprising: two or more customizableand replaceable foam sections positioned on a surface of a customizableand replaceable mattress core; a customizable and replaceable panelpositioned over the two or more customizable and replaceable foamsections; and at least one connection device comprising detachablymating connector portions, one of the detachably mating connectorportions secured adjacent at least a portion of an outer periphery ofthe customizable and replaceable panel and another of the detachablymating connector portions secured adjacent at least a portion of anotherouter periphery of the surface of the customizable and replaceablemattress core, the detachably mating connector portions of theconnection device detachably securing the customizable and replaceablepanel to the customizable and replaceable mattress core and retainingthe position of the two or more customizable and replaceable foamsections.
 2. The mattress as set forth in claim 1 wherein the two ormore customizable and replaceable foam sections further comprise twodifferent parallel foam sections positioned in a dual zoneconfiguration, each of the foam sections has a different foam comfortlevel.
 3. The mattress as set forth in claim 1 wherein the two or morecustomizable and replaceable foam sections further comprise threedifferent parallel foam sections positioned in a triple zoneconfiguration, at least two of the foam sections have a different foamcomfort level.
 4. The mattress as set forth in claim 1 wherein the twoor more customizable and replaceable foam sections further comprisethree different foam sections positioned in an asymmetric zoneconfiguration, at least two of the foam sections have a different shapeand at least two of the foam sections have a different foam comfortlevel.
 5. The mattress as set forth in claim 1 wherein the customizableand replaceable mattress core comprises a foam memory mattress core, anopen coil mattress core, or a pocket coil.
 6. The mattress as set forthin claim 1 wherein the customizable and replaceable mattress corecomprises two or more different customizable and replaceable mattresscore sections.
 7. The mattress as set forth in claim 6 wherein thecustomizable and replaceable mattress core comprises two or moredifferent customizable and replaceable mattress core layers.
 8. Themattress as set forth in claim 1 wherein the customizable andreplaceable panel comprises a padded fabric panel.
 9. The mattress asset forth in claim 1 wherein the connection device comprises at leastone zipper connector.
 10. A method for making a mattress, the methodcomprising: selecting one of a plurality of different customizable andreplaceable mattress cores; positioning two or more customizable andreplaceable foam sections on a surface of the selected one of theplurality of customizable and replaceable mattress cores; andpositioning a customizable and replaceable panel over the two or morecustomizable and replaceable foam sections; and detachably matingconnector portions of at least one connection device, one of thedetachably mating connector portions secured adjacent at least a portionof an outer periphery of the customizable and replaceable panel andanother of the detachably mating connector portions secured adjacent atleast a portion of another outer periphery of the surface of theselected one of the plurality of different customizable and replaceablemattress cores, the detachably mating connector portions of theconnection device detachably securing the customizable and replaceablepanel to the selected one of the plurality of different customizable andreplaceable mattress cores and retaining the position of the two or morecustomizable and replaceable foam sections.
 11. The method as set forthin claim 10 wherein the two or more customizable and replaceable foamsections further comprise two different parallel foam sectionspositioned in a dual zone configuration, each of the foam sections has adifferent foam comfort level.
 12. The method as set forth in claim 10wherein the two or more customizable and replaceable foam sectionsfurther comprise three different parallel foam sections positioned in atriple zone configuration, at least two of the foam sections have adifferent foam comfort level.
 13. The method as set forth in claim 10wherein the two or more customizable and replaceable foam sectionsfurther comprise three different foam sections positioned in anasymmetric zone configuration, at least two of the foam sections have adifferent shape and at least two of the foam sections have a differentfoam comfort level.
 14. The method as set forth in claim 10 wherein thecustomizable and replaceable mattress core comprises a foam memorymattress core, an open coil mattress core, or a pocket coil.
 15. Themethod as set forth in claim 10 wherein the customizable and replaceablemattress core comprises two or more different customizable andreplaceable mattress core sections.
 16. The method as set forth in claim15 wherein the customizable and replaceable mattress core comprises twoor more different customizable and replaceable mattress core layers. 17.The method as set forth in claim 10 wherein the customizable andreplaceable panel comprises a padded fabric panel.
 18. The method as setforth in claim 10 wherein the connection device comprises at least onezipper connector.